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Design Goals
The specifications for this design were chosen based on the power requirements of a medium power LCD
TV.
Table 1. Design Specifications
PARAMETER
VIN
VOUT
Output voltage
MIN
85
(VIN_MIN)
MAX
UNITS
265
(VIN_MAX)
63
Hz
300
390
47 Hz
(fLINE)
Line frequency
PF
POUT
Output power
fs
TYP
0.90
90%
200
kHz
Schematic
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Schematic
UCC28070 PFC controller in a two-phase average current mode control interleaved PFC pre-regulator.
DB
Vin
IIN
L1
IL1
DPA2
VOUT
D1
DRA
RFA
COUT
T1
1k
CFA
GDA
RTA
RFB
VCC=13V
DPA1
CTA
GDB
CCDR
RB1
UCC28070
DMAX 20
CDR
RDM
VAO
T2
L2
VINAC
GND 16
IMO
VCC 15
RSYNTH
CSB
CSA
PKLMT
IL2
T2
RA2
GDB 17
12V to 21V
Q2
CB4
RB2
GDA 14
CAOA
12
CAOB
11
RZCB
RSYN
RPK2
1.2nF
VREF 13
RIMO
RRDM
RZV
RR
SS 18
VSENSE
RPK1
CPV
CRR
RT 19
10
CB1
RSB
Q1
D2
DPB1
1.2nF
DRB
4.7pF
RTB
CZV
T1
220pF
DPB2
CTB
RR
CRR
4.7pF
1k
CFB
ROB
RA1
RSA
220pF
ROA
CB2
0.1uF
CB3
CSS
RRT
RDMX
0.1uF
CPCB
RZCA
CPCA
CZCB
CZCA
Inductor Selection
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Inductor Selection
One of the benefits of interleaved PFC boost pre-regulators is inductor ripple current reduction that is seen
at the input of the converter. The following equations and Figure 2 show the ratio of input ripple current
(IIN) to individual inductor ripple current (IL1) in a two-phase interleaved PFC as a function of duty cycle
(D). Because of this inductor ripple current cancellation, the designer can allow each inductor to have
more inductor ripple current than in a single stage design.
K(D) =
DIIN
DIL1
(1)
K(D) =
1- 2D
if D is < 05 = 0.5
1- D
(2)
K(D) =
2D - 1
if D is > 0.5
D
K(D)=DIIN/DIL1
(3)
D - Duty Cycle
Inductor Selection
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The following calculations are used to select the appropriate inductance for L1 and L2. Where, variable
DPLL is the converters duty cycle at the peak of low line operation. Variable K(DPLL) is the ratio of input
current to inductor ripple current at the peak of low line operation. IL is the boost inductor ripple current
at the peak of low line based on the converters input ripple current requirements.
DPLL =
VOUT - VIN_MIN 2
VOUT
390V - 85V 2
0.69
390 V
(4)
K(DPLL ) =
DIL =
2 0.69 - 1
= 0.55
0.69
POUT 2 0.3
300W 2 0.3
3.0 A
=
VIN_MIN h K(DPLL )
85V 0.90 0.55
L1 = L2 =
VIN_MIN
2 DPLL
DIL f s
85V 2 0.69
140 uH
2.96A 200 kHz
(5)
The following equation can be used to calculate total inductor RMS current (IL1_RMS and IL2_RMS).
IL1_RMS = IL2_RMS
POUT
2
VIN_MIN h
1p
L1 f s
VOUT
+
12
p 0
(6)
IL1_RMS = IL2_RMS
2
85V 2sin(q )
390V - 85V 2sin(q )
300W
1
140uH 200kHz
390V
2
=
+
12
85V 0.90 p 0
2A
(7)
A 140-mH boost inductor from Cooper Electronic Technologies part number CTX16-18060 was chosen for
the design. The inductance during normal operation will swing from 140mH to 350mH.
L1MIN = L2MIN = 140 uH
(8)
The average inductance is calculated for current loop compensation purposes. This will be used in the
current loop compensation section of the application note:
L1AVG = L2AVG =
L1MIN + L1MAX
140 uH + 350 uH
=
= 245 uH
2
2
(10)
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COUT
2 POUT
fLINE
VOUT 2 - (VOUT 0.75)2
2 300W
47 Hz
=
192 uF
2
2
(390V) - (292.5V )
(11)
Two 100-mF capacitors were used in parallel for the output capacitor.
COUT = 200 F
(12)
For this size capacitor the output peak to peak voltage ripple (VRIPPLE) is:
VRIPPLE
2 300W
2 POUT
1
0.90
=
=
14.5V
h
VOUT 2p 2fLINE COUT
390V 2 2 47Hz 200 F
(13)
In addition to holdup requirements, a capacitor must be selected so that it can withstand both the
low-frequency RMS current (ICOUT_LF) and the high-frequency RMS current (ICOUT_HF). High-voltage
electrolytic capacitors generally have both low frequency (100 Hz to 120 Hz) and high frequency RMS
current ratings on their data sheets.
ICOUT_LF =
POUT
h VOUT 2
300W
0.90 390V
0.604A
(14)
ICOUT_HF
P
= OUT
h VOUT
16 VOUT
6p VIN_MIN
- h - ICOUT_LF
(15)
300W
ICOUT_HF =
0.90 390V
2
- (0.90)2 - (0.604 ) 1.0A
6p 85V 2
16 390V
(16)
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300W 2
2.97A
+
1.2 5.1A
2
2 85V 0.90
(17)
IDS =
POUT
2 VIN_MIN 2
2 -
16 VIN_MIN 2
3 p VOUT
300W
16 85V 2
0.90
=
2 1.685A
3 p 390V
2 85V 2
(18)
POUT
300W
=
0.39A
VOUT
2 390V
(19)
Current Sense Transformers Setup and Selection (T1, T2, DRA, DRB)
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Current Sense Transformers Setup and Selection (T1, T2, DRA, DRB)
The current sense transformer is selected to handle IPEAK and have a peak current sense signal (IRS) of
roughly 100 mA.
NCT =
NS
I
5.1A
PEAK =
= 51
NP
IRS
0.1A
(20)
For this design a current sense transformer with a turns ratio (NCT) of 50 was chosen for the design.
NCT = 50
(21)
The magnetizing inductance (LM) of the current sense transformer should be selected or designed so the
magnetizing current is less than 2% of the maximum current sense signal. The following equation
calculates the minimum LM where VS is the maximum current sense signal voltage. For this design a
current sense transformer was designed by Cooper Electronic Technologies (CTX16-18294) with a
magnetizing inductance of 8.25 mH.
LM
VOUT - VIN_MIN 2
VS
3.7V
390V - 85V 2
6.24mH
=
IPEAK
5.1A
VOUT
390V
0.02 200kHz
0.02 f s
50
NCT
(22)
LM = 8.25 mH
(23)
Selection of the current sense resistors (RSA and RSB ) is based on the peak current limit signal (VS) and
the peak current on the secondary side of the current sense transformer. A factor of 0.9 was multiplied by
the current sense signal to leave room for the 10% PWM ramp that is used to make this design more
noise immune at lighter loads.
RSA = RSB =
0.9 VS
0.9 3.7V 50
=
32.5 W
IPEAK
0.102A
NCT
(24)
RS DMAX
33.2 W 0.97
=
; 1 kW
1 - DMAX
1 - 0.97
(26)
Current sense transformers rectifying diodes (DR) need to be designed to withstand the current sense
transformers reset voltage (VR):
VR = IPEAK
NP
5.1A 1 kW
RR =
103V
NS
50
(27)
Current Sense Transformers Setup and Selection (T1, T2, DRA, DRB)
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To improve noise immunity at extremely light loads, a PWM ramp with a dc offset is recommended to be
added to the current sense signals. Electrical components RTA, RTB, CTA, CTB, DPA1, DPA2, DPB1, and DPB2
form a PWM ramp that is activated and deactivated by the gate drive outputs of the UCC28070. Resistor
ROA and ROB add a DC offset to the CS resistors (RSA and RSB).
When the inductor current becomes discontinuous the boost inductors ring with the parasitic capacitances
in the boost stages. This inductor current rings through the CTs causing a false current sense signal.
Refer to the following graphical representation of what the current sense signal looks like when the
inductor current goes discontinuous. Note that the inductor current and VRSA may vary from this graphical
representation depending on how much inductor ringing is in the design when the unit goes discontinuous.
GDA
IL1
0A
VRSA
VOFF
0V
Discontinues Current Causes False Current Sense Signal
Figure
3. False Current Sense Signal
Current Sense Transformers Setup and Selection (T1, T2, DRA, DRB)
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To properly select the offset (VOFF) just requires adjusting resistors ROA and ROB to add a dc offset to the
current sense resistors, that is high enough to block DRA and DRB from conducting when a false current
sense signals is present. This occurs when the inductors are operating with discontinuous inductor current
and was described above in detail. Setting the offset to 200 mV is a good starting point and may need to
be adjusted based on individual design criteria and the amount of noise and parasitic elements present in
the system.
VOFF = 0.2 V
(28)
ROA = ROB =
(VVCC
- VOFF )RSA
VOFF
(13V
- 0.2V ) 33.2
0.2V
2.1 kW
(29)
RTA =RTB =
(VVCC - (Vs 0.1- VOFF +VDPA2 )RSA (13V - (3.7V 0.1- 0.2V)+0.6V ) 33.2
Vs 0.1- VOFF
2.62 kW
(31)
CTA = CTB =
RSA
1
50 nF
fS 3
(33)
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VS RPK1
3.7V 3.65 k
=
5.9 kW
VREF - VS
6V - 3.7V
(35)
7.5 109 W Hz
7.5 109 W Hz
=
= 37.5 kW
fs
200 kHz
(36)
Resistor RDMX was selected to set the maximum duty cycle clamp (DMAX) to 0.97:
RDMX = RRT (2 DMAX - 1) = 37.4 k (2 0.97 - 1) = 35 k W
(38)
Programming VOUT
Resistor RA is selected to minimize the error due to VSENSE input bias current and to minimize loading on
the power line when the PFC is disabled. Construct resistor RA from two or more resistors in series to
meet high voltage requirements. Resistor RB is sized to program the converters output voltage (VOUT).
RA = 3M W
(40)
VREF
RA
3V 3M
2
RB =
=
23.3 kW
VREF
390V
3V
VOUT 2
(41)
The resistor divider formed by RA and RB from the output voltage to the VSENSE pin also sets the over
voltage protection threshold (VOVP).
VOVP = 3.18V
R A + RB
3MW + 23.2 kW
= 3.18V
414V
RB
23.2 kW
(43)
10
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10
VVREF
3V
=
0.0077
VOUT
390V
(45)
Output impedance (ZO) is required to attenuate the low frequency boost capacitor output ripple (VRIPPLE) to
less than 3% of the effective voltage amplifier output range (VAO). This impedance is set by properly
selecting feedback capacitor CPV:
ZO =
3.2V 0.03
DVAO 0.03
=
12.3 kW
VRIPPLE H gmV
14.5V 0.0077 70 m S
(46)
CPV =
1
1
=
138nF
2p 2 fLINE Zo 2p 2 47Hz 12.3kW
(47)
11
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For the highest possible power factor the voltage loop crossover frequency (fCV) needs to be set based on
the following equation:
DVAO = 3.2 V
(49)
fCV = H gmV
1
POUT
j 2p COUT
1
VOUT
2 p CPV
DVAO
(50)
fCV
300W
1
1
= 0.0077 70m S 0.90
11Hz
3.2V 2 p 200mF 390V 2 p 150nF
(51)
Voltage compensation resistor RZV is then sized to put a pole at the converters voltage loop crossover
frequency:
R ZV =
1
1
=
96.4 kW
2p fCV CPV
2p 10.6Hz 150nF
(52)
Voltage compensation capacitor CZV is used to increase the dc gain of the voltage loop and gives some
added phase margin before crossover. The zero added to the voltage loop needs to be set at 1/10th the
crossover frequency.
CZV =
1
1
1.5 mF
=
11Hz
fCV
2p
100 kW
2p
R ZV
10
10
(54)
12
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The following equations can be used to estimate voltage compensation network gain, voltage loop power
stage gain and voltage loop gain. These equations can also be used to graphically check loop stability.
Voltage Compensation Network Gain (GCV(f)) as function of frequency:
GCV (f ) =
DVVAO
= H gmV
DVOUT
j 2p f R ZV CZV +1
CZV CPV
+1
(j 2p f (CZV + CPV )) j 2p f C RZV
ZV +CPV
(55)
GPSV (f ) =
DVOUT
DVVAO
1
POUT
j 2p f COUT
VOUT
DVAO
(56)
Figure 4 shows the theoretical loop gain (TvdB(f)) as a function of frequency and Figure 5 shows the
theoretical loop phase (qv(f)) as a function of frequency. From these figures it can be observed that the
voltage loop crossed over at roughly 9 Hz with a phase margin of 60 degrees. Compensating the voltage
loop is not an exact science and should be checked with a network analyzer and adjusted if necessary.
90
90
90
90
60
75
30
TvdB ( f)
60
qv( f)45
30
30
60
15
- 90
90
1
1
10
100
f
3
1 .10
110
0
0
1
1
10
1 .10
100
f
110
13
11
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NCT L1MAX
RSYN =
RS
(58)
The IMO resistor needs to be set with the following equation to center the digitized multiplier for universal
line applications:
IMO =
130 m A
(60)
VI =
0.76V (R A + RB )
RB
70V
(61)
V2 =
1.1 POUT 2
1
1.1 300W 2
1
RS =
33.2W 2.458V
NCT
2 h V 1
2 0.92 72V 50
(62)
RIMO =
V2
2.458 V
=
18.9kW
IMO
130 m A
(63)
th
The current loop in a PFC converter is generally designed to crossover at between 1/10 and 1/6 the
converters switching frequency. The current loop in this design example is going to be designed to
crossover at 1/10th of the single stages switching frequency. In order to properly compensate the current
loop it is required to calculate the current loop's power stage gain (GPS) at the current loop's crossover and
properly select passive components RZC1/2, CZC1/2 and CPC1/2:
VOUT RS
GPSC =
2p
1
NCT
fs
L1AVG VRAMP
10
390 V 33.2W
=
2p
1
50
200 kHz
245 mH 4.0V
10
2.1
(65)
14
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R ZC1 = R ZC2 =
gmC
1
1
=
= 4.8 kW
GPSC
100 m S 2.1
(67)
CZC1 = CZC2 =
1
1
1.7nF
=
fs
200 kHz
4.8 kW
2p
2p
R ZC
10
10
(68)
CPC1 = CPC2 =
1
1
333 pF
=
fs
200 kHz
2p
R ZC
2p
4.8 kW
2
2
(69)
Standard components close to the calculated values are chosen for the current loop compensation:
R ZC1 = 4.02 kW, CZC1 = 2.2 nF, CPC1 = 330 pF
(70)
Graphically Check Theoretical Current Loop Gain (TcdB(f)) and loop phase (qc(f)): From the plots in
Figure 6 and Figure 7 it can be observed that the theoretical loop gain crossed over at roughly 20 kHz
with a phase margin of roughly 39 degrees.
VOUT Rs P
NS
j 2p f R ZC CZC +1
TcdB(f ) = 20log
gmC
j 2p f L1 DVRAMP
j
2
R
C
C
p
f
ZC
ZC
PC
j 2p f (CZC +CPC ))
+1
(
CZC +CPC
(71)
200
180
200
180
133.33
150
66.67
120
TcdB( f)
qc( f) 90
66.67
60
133.33
- 200
30
200
1
10
100
1 .10
1 .10
1 .10
1 .10
6
110
0
0
1
10
100
1 .10
1 .10
1 .10
1 .10
6
110
15
Soft Start
12
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Soft Start
To have a controlled soft start the CSS capacitor needs to be set to at least the same value as the CZV
capacitor or larger. This means the design has a minimum soft start time based on the CZV capacitor
t SSMIN =
2.25 V CZV
2.25V 1.5 mF
338 ms
=
10 m A
10 m A
(72)
CSS CZV
(73)
The soft-start timing can be set with timing capacitor CSS once the amount of soft start time (tSS) has been
determined. Our original design requirement was to have 200 ms of soft-start time. The calculated
capacitance needed for this soft-start time is less than the minimum required capacitance.
Css =
10 m A t ss
10 m A 200 ms
0.889 mF
=
2.25V
2.25 V
(74)
A CSS capacitor value equal to the CZV capacitor was chosen for the design.
Css = 1.5 mF
(75)
13
fDR = 10kHz
(77)
6
RRDM =
937.5 10 W
937.5 10 W
=
= 31.13 kW
fDM
30 kHz
(78)
CCDR =
CCDR = 220 pF
(81)
16
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14
17
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U1
UCC27324D
18
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19
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VOUT
RETURN
C5
HS1
C2
L1
L2
C6
D5
T1
C7
T2
D6
J1
RT1
C2
Q1
VAR1
Q1
F1
HS3
HS2
C11
AC LINE
VCC
AC NEUTRAL
J2
SYNC
GND
VOUT
RETURN
JP2
D1
JP2
D3
R5
D13
R3
C3
D4
R2
R4
C8
C12
R13 R1
R11
C9
D10
R8
U1
D7 R6
C4 D8
R18
J1 R12 R7
R17
R9 R10
D2
R15
R19
D9
AC NEUTRAL
AC LINE
20
Efficiency Curves
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15
Efficiency Curves
A 300-W prototype was built based on the design information presented in this application note. The
following graphs show the performance of this EVM.
100%
100%
98%
98%
96%
96%
94%
94%
% Efficiency
% Efficiency
Efficiency
92%
90%
92%
90%
88%
88%
86%
86%
84%
82%
80%
10%
20%
30%
40%
50%
84%
82%
60%
70%
80%
90%
80%
10%
100%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% Output Power
% Output Power
Figure 14.
Figure 15.
Current Harmonics V IN = 230V, POUT = 300W
1.41473
1.17894
0.94316
Amplitude (A)
0.70737
0.47159
0.23580
0.00001
1
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
Harmonic
21
Efficiency Curves
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0.990
0.990
0.980
0.980
0.970
0.970
0.960
0.960
PF
PF
Pow er Factor
1.000
0.950
0.950
PF VIN = 230V
PF VIN = 265V
0.930
0.930
0.920
0.920
0.910
0.910
0.900
20%
30%
40%
50%
60%
70%
80%
90%
PF VIN = 115V
0.940
PF VIN = 85V
0.940
0.900
20%
100%
30%
22
40%
50%
60%
70%
80%
90%
100%
% Output Pow er
% Output Pow er
Figure 17.
Efficiency Curves
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23
Efficiency Curves
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24
Efficiency Curves
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15.4 Recovery from Line Dropout, CH1= Rectified Line Voltage, CH2=IL1, CH3=IL2, CH4 =
VOUT
25
References
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Figure 29. EMI Quasi Peak (QP) Measurement with out Frequency Dithering, No EMI Filter Present
Figure 30. EMI Quasi Peak (QP) Measurement with Frequency Dithering, No EMI filter Present
16
References
1. Lazlo Balogh and Richard Redi, Power Factor Correction with Interleaved Boost, APEC 1993, pp.
168-174
2. Lloyd Dixon, High Power Factor Switching Pre-regulator Design Optimization, Unitrode Power Supply
Design Seminar SEM-700, 1990, Topic 7
3. Brett Miwa, David Otten, Martin F. Schlecht, High Efficiency Power Factor Correction Using Interleaved
Techniques IEEE 1992, pp. 557 to 568
4. Michael OLoughlin, 350W, Two Phase Interleaved PFC Pre-regulator Design Review, Texas
Instrument Literature Number SLUA369, 2006
5. Michael OLouglin, An Interleaving PFC Pre-Regulator for High-Power Converters Unitrode/TI Power
Supply Design Seminar SEM-1700, Topic 5
6. P. Zumel, O. Garcia, J. A. Cobos, J. Uceda, EMI Reduction by Interleaving of Power Converters
Presentation, APEC 2004
7. UCC28070 Data Sheet, Texas Instruments Literature Number SLUS794,
http://focus.ti.com/lit/ds/symlink/ucc28070.pdf
26
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products in automotive applications, TI will not be responsible for any failure to meet such requirements.
Following are URLs where you can obtain information on other Texas Instruments products and application solutions:
Products
Applications
Amplifiers
amplifier.ti.com
Audio
www.ti.com/audio
Data Converters
dataconverter.ti.com
Automotive
www.ti.com/automotive
DLP Products
www.dlp.com
Communications and
Telecom
www.ti.com/communications
DSP
dsp.ti.com
Computers and
Peripherals
www.ti.com/computers
www.ti.com/clocks
Consumer Electronics
www.ti.com/consumer-apps
Interface
interface.ti.com
Energy
www.ti.com/energy
Logic
logic.ti.com
Industrial
www.ti.com/industrial
Power Mgmt
power.ti.com
Medical
www.ti.com/medical
Microcontrollers
microcontroller.ti.com
Security
www.ti.com/security
RFID
www.ti-rfid.com
www.ti.com/space-avionics-defense
www.ti.com/video
Wireless
www.ti.com/wireless-apps
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